Novel polymers of olefin terminated prepolymers and amine terminated prepolymers

ABSTRACT

New and useful polymers are prepared by reacting olefin-terminated prepolymeric materials with simple polyamine, by reacting simple olefins with amine-terminated prepolymers and by reacting olefin-terminated prepolymers with amine-terminated prepolymers. The new and useful polymeric materials so obtained can be cured as with heat, with or without catalyst, to provide products useful for preparing films, laminates, composites, prepregs, molding materials, varnishes, wire enamels and the like.

This is a division of application Ser. No. 208,929, filed Dec. 16, 1971,now U.S. Pat. No. 4,020,303, issued Apr. 26, 1977.

This invention relates to new and useful polymeric materials which canbe cured or cross-linked to provide compositions useful for preparingfilms, laminates, composites, prepregs, molding materials, varnishes,wire enamels and the like. More particularly, the invention relates topolymeric reaction products of olefin-terminated prepolymer materialswith simple polyamine, by reacting simple olefins with amine-terminatedprepolymers, and by reacting olefin-terminated prepolymers withamine-terminated prepolymers. The polymeric materials so obtained can becured as with heat, with or without catalyst, to provide useful productsincluding those mentioned above.

It has been known in the past to react simple polyamines such asdiamines with simple bisolefins as pointed out, for example in U.S. Pat.No. 3,562,223, Feb. 9, 1971. While such materials are possessed ofuseful properties, it has been found desirable to have materials whichwill be characterized by even more enhanced thermal and other physicalproperties and it is a primary object of this invention to provide suchmaterials.

Briefly, according to the present invention, there are reacted togethersimple polyamines and olefin-terminated prepolymers or amine-terminatedprepolymers and olefins such as bisolefins or amine-terminatedprepolymers and olefin-terminated prepolymers to provide new polymericmaterials which can be cured with heat, with or without the use ofcatalyst to provide useful products.

Those features of the invention which are believed to be novel are setforth with particularity in the claims appended hereto. The inventionwill, however, be better understood and further objects and advantagesappreciated from a consideration of the following description.

Useful in connection with the present invention are simple polyaminesexpressed by the formula

    X--R"--(NH.sub.2).sub.n

where R" is an organic radical and n is at least 2 and X is hydrogen, anamino group or substituted or unsubstituted organic group includingthose also containing at least one amino group. The specific aminesuseful for the present invention, alone or in admixture, include but arenot limited to the following:

p-xylylene diamine

bis(4-amino-cyclohexyl)methane

hexamethylene diamine

heptamethylene diamine

octamethylene diamine

nonamethylene diamine

decamethylene diamine

3-methyl-heptamethylene diamine 4,4'-dimethylheptamethylene diamine

2,11-diamino-dodecane

1,2-bis-(3-amino-propoxy)ethane

2,2-dimethyl propylene diamine

3-methoxy-hexamethylene diamine

2,5-dimethylhexamethylene diamine

2,5-dimethylheptamethylene diamine

5-methylnonamethylene diamine

1,4-diamino-cyclo-hexane

1,12-diamino-octadecane

2,5-diamino-1,3,4-oxadiazole

H₂ N(CH₂)₃ O(CH₂)₂ O(CH₂)₃ NH₂

H₂ N(CH₂)₃ S(CH₂)₃ NH₂

H₂ N(CH₂)₃ N(CH₃)(CH₂)₃ NH₂

meta-phenylene diamine

para-phenylene diamine

4,4'-diamino-diphenyl propane

4,4'-diamino-diphenyl methane

benzidine

4,4'-diamino-diphenyl sulfide

4,4'-diamino-diphenyl sulfone

3,3'-diamino-diphenyl sulfone

4,4'-diamino-diphenyl ether

2,6-diamino-pyridine

bis(4-amino-phenyl)diethyl silane

bis(4-amino-phenyl)diphenyl silane

bis(4-amino-phenyl)phosphine oxide

4,4'-diaminobenzophenone

bis(4-amino-phenyl)-N-methylamine

bis(4-aminobutyl)tetramethyldisiloxane

1,5-diaminonaphthalene

3,3'-dimethyl-4,4'-diamino-biphenyl

3,3'-dimethoxy benzidine

2,4-bis(beta-amino-t-butyl)toluene

toluene diamine

bis(para-beta-amino-t-butyl-phenyl)ether

isomeric trimethyl hexamethylene diamine

para-bis(2-methyl-4-amino-pentyl)benzene

para-bis(1,1-dimethyl-5-amino-pentyl)benzene

m-xylylene diamine

polymethylene polyaniline of formula ##STR1## where m is from about 0.1to 10 and preferably about 0.3.

Materials which have been found useful in reacting with polyamine toprepare amine-terminated prepolymers include diacids expressed by theformula

    HOOC--R--COOH

where R is an unsaturated or saturated, substituted or unsubstituted,aliphatic group containing from about 1 to 40 carbon atoms. Among suchdiacids are oxalic, succinic, glutaric, adipic, pimelic, suberic,azelaic, sebacic and dodecanedioic acids, as well as unsaturated acidsfalling within the above formula including maleic and fumaric acids,among others. Mixtures can, of course, be used. A dibasic acid having achain thirty-six carbons long is Emery Industries, Inc. 3713-R DimerAcid. Others will occur to those skilled in the art.

The group R in the above formula can also be an aromatic group providingmaterials typified by terephthalic and isophthalic acid. Anhydrides ofsuch acids are useful as well.

Also useful as the acidic component are tricarboxylic acid anhydridematerials which can be expressed by the following formula ##STR2## whereR' is a trivalent organic radical. Among such materials which will occurto those skilled in the art are trimellitic anhydride; 2,6,7-naphthalenetricarboxylic anhydride; 3,3',4-diphenyl tricarboxylic anhydride;3,3',4-benzophenone tricarboxylic anhydride; 1,3,4-cyclopentanetetracarboxylic anhydride; 2,2',3-diphenyl tricarboxylic anhydride;diphenyl sulfone-3,3',4-tricarboxylic anhydride; diphenyl isopropylidene3,3',4-tricarboxylic anhydride; 3,4,10-propylene tricarboxylicanhydride; 3,4-dicarboxyphenyl 3-carboxyphenyl ether anhydride; ethylenetricarboxylic anhydride; 1,2,5-naphthalene tricarboxylic anhydride; etc.Also useful are the corresponding acids of such anhydrides. Wherediacids are mentioned, such substitutions will be understood to beincluded.

The olefin group-containing material of the present invention isconveniently derived from anhydrides of the formula ##STR3## where D isan aliphatically unsaturated divalent organic radical ##STR4## where Yis a radical selected from hydrogen, lower alkyl, halogen, or mixturesthereof, such as chloromethyl, ethyl, propyl, bromo, and the like.Examples of such materials include maleic anhydride, citraconicanhydride and itaconic anhydride, among others.

Also useful in the present respect are bisimides which can be expressedby the formula ##STR5## where R'" is a group containing at least twocarbon atoms and D is as above. Materials of these types include, amongothers, maleic N,N'-ethylene-bis-imide, maleicN,N'-hexamethylene-bis-imide, maleic N,N'-methaphenylene-bis-imide,maleic N,N'-paraphenylene-bis-imide, maleicN,N'-4,4'-diphenylmethane-bis-imide, maleicN,N'-4,4'-diphenylether-bis-imide, maleicN,N'-4,4'-diphenylsulphone-bis-imide, maleicN,N'-4,4'-dicyclohexylmethane-bis-imide, maleicN,N'-α,α'-4,4'-dimethylenecyclohexane-bis-imide, maleicN,N'-metaxylylene-bis-imide, and maleicN,N'-4,4'-diphenylcyclohexane-bis-imide and their corresponding amideacids. Also useful are materials derived from polyfunctional amines suchas polymethylene, polyaniline, and others.

Any non-reactive solvent which will satisfactorily dissolve theingredients can be used including, among others, N,N'-dimethylacetamideand N-methylpyrrolidone, dimethyl formamide, cresylic acid andcompatible mixtures of such with hydrocarbon and other compatiblesolvents.

The ingredients can be used in equivalent proportions or with an excessof olefin material.

The following examples will illustrate the practice of the presentinvention, it being understood that they are not to be taken as limitingin any way.

EXAMPLE A

This example illustrates the preparation of amine-terminated prepolymer.Under nitrogen and anhydrous conditions, a solution of trimelliticanhydride monoacid chloride (TMAC) (13.47 g, 64 m moles) in dryN,N'-dimethylacetamide (DMAC) was added at -20° C. during 10 minutes toa stirred solution of triethylamine (6.46 g, 64 m moles) and methylenedianiline (MDA) (15.84 g, 80 m moles) in DMAC to give a solutioncontaining 108 g of DMAC and precipitated triethylamine hydrochloride.The mixture was stirred without the cooling bath for one hour, cooled to0° C., and filtered to remove triethylamine hydrochloride (8.5 g). Thesolution was refrigerated and portions used as such as required.

EXAMBLE B

The olefin terminated prepolymer is prepared by reacting amineterminated prepolymer with an olefin containing material having an aminereactive functional group. This particular example illustrates thepreparation of a maleimide-terminated prepolymer. A solution prepared bythe procedure of Example A was used as follows. The solution was cooledto -20° C. and treated with a solution of maleic anhydride (3.45 g, 35.2m moles) in DMAC (15.84 g). The resulting solution was diluted with DMAC(14.87 g) and stored at room temperature overnight. Sodium acetate (1.11g) and acetic anhydride (19.58 g) were added and the solution was keptat 53°-56° C. for 2 hours, cooled and stirred 4 hours, left overnight,precipitated into water, washed and dried to give 26.5 g of solids.

EXAMPLE C

This example illustrates the preparation of amine-terminated prepolymerusing trimellitic anhydride (TMA) as the acidic constituent. A solutionof MDA (297 g, 1.5 mole) in N-methylpyrrolidone (MP) (207.5 g)containing xylene was treated at 180° C. with TMA (230.4 g, 1.09 moles)added portionwise. Heating was continued for 21 hours at 150°-210° C.using triethyl phosphite (1.5 g added as 3 portions) as a catalyst.Titration of residual carboxyl showed the reaction to be essentially 100percent complete. The product was diluted to 25% solids with MP and usedas such.

EXAMPLE D

This example illustrates the preparation of maleimide-terminatedprepolymer from the material of Example C. A portion (472 g) of theabove solution was treated with stirring under nitrogen at 40° C. withmaleic anhydride (15.7 g, 0.16 mole). Then acetic anhydride (32.6 g) andsodium acetate (1.8 g) were added and the solution was kept at 55°-58°C. for 2 hours, cooled, allowed to sit overnight, precipitated intowater, filtered, washed, and dried to give 128 g of solids product.

EXAMPLE E

This example illustrates the in situ preparation of4,4'-bis(trimellitimido) diphenylmethane and its use as a monomer togive a polyamide-imide polyamine. Under nitrogen and anhydrousconditions, MDA (59.4 g) was added at 100° C. to a stirred solution ofTMA (115.2 g) in MP solvent (174.6 g) containing xylene. Water (10.8 g)was collected during 2.5 hours in the range of 137°-186° C. Thissolution was cooled to 155° C. and MDA(90.1 g) and triphenyl phosphite(0.5 g) were added. The system was heated at 170°-210° C. for 18 hours.The reaction was essentially 100% complete by titration for residualcarboxylic acid. After cooling, the solution was diluted with 483 g ofMP and used as such.

EXAMPLE 1

A maleimide-terminated amide-imide prepolymer was made by the procedureof Example B except that the mole ratio of MDA:TMAC was 2:1. Then, 25 g(35.1 m moles) of the above solid was added with stirring under nitrogento 111.2 g of dimethyl acetamide (DMAC) followed by 2.8 g (17.6 m moles)of trimethylhexamethylenediamine. The solution was heated to 50° C.,treated with 0.03 g of hydroquinone, heated to 125° C., held for onehour, allowed to cool, precipitated into water with a Waring Blender,filtered, washed and dried. By differential thermal analysis (DTA), theglass transition temperature (Tg) of the powder was 170°-175° C.

A one-gram portion of the powder was placed between sheets of aluminumfoil, in turn between press plates, and in turn between 4-ply of paddingfor each plate. A thermo-couple was used to measure temperature on anelectrically heated press, and the sample was heated with contactpressure. Flow was observed at 150°-185° C. Then the sample was pressedat 10,000 psi and 220°-245° C. for 15 minutes, cooled, and removed togive a strong and flexible, transparent red film 21 mils thick.

EXAMPLE 2

A sample of the maleimide-terminated prepolymer (25 g, 35.1 m moles) asused in Example 1 was dissolved in DMAC (111.2 g) and treated by theprocess of Example 1 with a blend of diamines consisting ofm-phenylenediamine (0.8 g, 7.04 m moles), methylenedianiline (1.47 g,7.04 m moles), and trimethylhexamethylenediamine (0.6 g, 3.52 m moles)and then hydroquinone (0.03 g). After heating as in Example 1 andobtaining the powdered product, the Tg was found to be about 140° C. byDifferential Thermal Analysis (DTA). A 1 g sample was molded as inExample 1, a pressure drop being observed at 275°-320° F. The sample washeld at 375°-450° F. for 15 minutes at 4000 psi. A transparent 13-milorange film which was very strong and flexible was obtained.

EXAMPLE 3

Using a maleimide-terminated prepolymer prepared by the procedure ofExample B, a portion (25 g, 14.1 m moles) was dissolved in DMAC (103.2g) and reacted as in Example 1 with m-phenylenediamine (0.8 g, 7 mmoles) and hydroquinone (0.03 g). The powdered reaction product wasmolded as in Example 1. A pressure drop was observed at 155°-220° C. andthe sample was pressed at 220°-290° C. for 10 minutes at 10,000 psi. Adark orange transparent film was obtained which was very strong andflexible.

EXAMPLE 4

A sample of the maleimide-terminated prepolymer (25 g, 14.1 m moles) asused in Example 3, oxydianiline (1.4 g, 7 m moles) and hydroquinone(0.03 g) in DMAC (105.6 g) were reacted and isolated as in Example 1.The product had a Tg of about 180° C. On molding a 1 g sample as inExample 1, a pressure drop was observed at 150°-180° C. with contactpressure. The sample was pressed at 215°-275° C. for 17 minutes at10,000 psi to give a strong and flexible transparent orange film.

EXAMPLE 5

A sample of the maleimide-terminated material (25 g, 14.1 m moles) usedas in Example 4 was treated with diaminodiphenylsulfone (1.7 g, 7 mmoles) in DMAC (106.8 g) with hydroquinone as in Example 1. A portion ofthe product (1 g) was molded as in Example 1. A pressure drop at140°-200° C. was observed. The sample was pressed at 240°-265° C. for 12minutes at 10,000 psi to give a brownish-orange strong and transparentfilm.

EXAMPLE 6

A sample of maleimide-terminated prepolymer (11.4 g, 4 m moles) preparedby the procedure of Example B where the MDA:TMA-acid chloride molarratio was 8:7 was dissolved in 50 ml of N-methylpyrrolidone (MP), heatedto 155° C., treated with MDA (0.4 g, 2 m moles) with stirring, held at110°-125° C. for 40 minutes, cooled, precipitated into water, filtered,washed, and dried. Films were cast from dimethylformamide (DMF) and wereflexible after curing.

EXAMPLE 7

The intermediate prepolymer diamine used in this example was prepared bythe procedure of Example A from 2 moles of methylene dianiline and 1mole of trimellitic anhydride acid chloride. Into a flask were placed3.8 g (0.0067 mole) of the prepolymer diamine, 18.7 g (0.052 mole) ofthe bismaleimide of methylene dianiline and 60 ml of DMF. The solutionwas heated to 100° C. and 25 ml of xylene and 10 ml of DMAC were added.The temperature was increased to 150° C. and maintained there for 40minutes. Methanol (160 ml) and DMF (100 ml) were added. The product wasisolated by precipitation into 1100 ml of a 10:1 mixture ofmethanol/water, collected by filtration, slurried twice in benzene,collected by filtration and dried. Analysis of the product's infraredspectrum indicated that the desired reaction had taken place. The powderwas molded at 240° C. and 3,000 psi for 20 minutes to produce a bar.

EXAMPLE 8

The intermediate prepolymer diamine was prepared by the procedure ofExample A from 2 moles of methylene dianiline and 1 mole of isophthaloylchloride. The prepolymer diamine (10.0 g, 0.01 mole) was dissolved withstirring at about 115° C. into 300 ml of DMF which contained 1.4 g oflithium chloride to aid dissolution. The bismaleimide of methylenedianiline (13.3 g, 0.037 mole) was added and the temperature maintainedfor 45 minutes. The reaction mixture was allowed to cool to 40° C. Theproduct was isolated by precipitation into water followed by collectionby filtration. The product was slurried with acetone to aid drying,collected by filtration, washed wtih benzene and then with hexane priorto drying. Cured molded parts were made from this product.

EXAMPLE 9

Into a flask were placed 104 g of a DMAC solution containing 16.6 g(0.0059 mole) of a prepolymer amine prepared from 8 moles of methylenedianiline and 7 moles of trimellitic anhydride mono acid chloride by theprocedure of Example A. Eighty cc of xylene were added and ring closureof the amic acid to the imide was accomplished (as determined byinfrared analysis) by azeotropic distillation. To this solution at 115°C. were added 3.6 g (0.010 mole) of the bismaleimide of methylenedianiline. An immediate color change was noted. The reaction mixture waskept at 110°-120° C. for 40 minutes prior to precipitation of theproduct via dripping into 1.5 liters of water. The yellow solid wascollected by filtration, washed with water and then hexane prior todrying. The product was found to be soluble in polar solvents. Filmswere cast from DMF at 30 percent solids on glass. They were cured for0.5 hour at 120° C., 1 hour at 200° C. and finally at 1.5 hours at 250°C. These films were flexible.

EXAMPLE 10

The prepolymer bismaleimide (11.4 g) prepared from MDA and trimelliticanhydride, monoacid chloride in a ratio of 8:7 followed by treatmentwith maleic anhydride and subsequent ring closure using the procedure ofExample B was dissolved in 50 ml of N-methylpyrrolidone. The solutionwas heated to 115° C. and 0.4 g (0.002 mole) of MDA was added withstirring. The solution darkened. After heating (110°-125° C.) for 40minutes, the solution was cooled to 40° C. and then dripped into 300 mlof water. The resulting yellowish solid was collected by filtration andwashed with water and then hexane prior to drying. The product was foundto be soluble in polar solvents. Films cast from dimethylformamidesolution on glass slides were found to be flexible after curing andremoval from the glass.

EXAMPLE 11

An amine-terminated prepolymer solution made by the procedure of ExampleC (50.5 g, containing 7.88 m moles of diamine) was heated to 115°-120°C. and treated with a solution of 4,4'-bismaleimidodiphenylmethane (5.66g, 15.8 m moles) in N-methylpyrrolidone (104.2 g) and kept at 112°-115°C. for 1.75 hours. The product was precipitated, filtered, washed anddried to give 15.5 g of product. The glass transition temperature (Tg)was 190° C. by differential thermal analysis (DTA). By thermalgravimetric analysis (TGA) in air (heating rate 4.5° C./min.), thepowder had a T₂₀ (temperature at 20 percent weight loss) of 470° C.Cured, flexible films and tough molded articles are prepared from thiscomposition.

EXAMPLE 12

A maleimide-terminated prepolymer solid made by the procedure of ExampleD (20 Og, 11.3 m moles) was dissolved in N-methylpyrrolidone (70 g). At113° C., a solution of MDA (1.1 g) in NMP (50 g) was added withstirring. After keeping the solution at 110°-112° C. for 20 minutes, theproduct was precipitated, filtered, washed, and dried to give 18.7 g ofproduct. By TGA as in Example 10, the powder had a T₂₀ of 450° C. Cured,flexible films and tough molded articles were prepared from thiscomposition.

EXAMPLE 13

A portion of the solution made by Example E (31.15 g containing 4.92 mmoles of diamine) was diluted with MP solvent (16.22 g), then treatedwith a solid maleimide-terminated prepolymer made by the procedure ofExample D (8.728 g, 4.92 m moles), rolled in a jar for 20 minutes atroom temperature, placed in a 110° C. oven for 25 minutes, rolled for 35minutes further to give a dark solution.

A film was cast on a glass plate and cured one hour each at 120°, 200°,250° C., and 15 minutes at 316° C. The film was removed by soaking inhot water for two hours and was flexible.

EXAMPLE 14

A mixture of MDA (990 g, 5 moles), TMA (777.6 g, 4.05 moles), azelaicacid (84.6 g, 0.45 mole), a cresol-phenol solvent (794 g) and xylene(175 ml) was heated for 13.5 hours in the range of 130°-200° C. with acollection of water of condensation. The product was diluted witn1,984.5 g of cresol-phenol solvent.

A second reaction was run using MDA (594 g, 3 moles), TMA (466.6 g, 2.43moles), azelaic acid (50.8 g, 0.27 mole), cresol-phenol solvent (476 g)and xylene (100 ml). Water of condensation was collected during ninehours in the range of 140°-200° C. The product was diluted with 1191 gof cresol-pehnol solvent.

The two reaction products were combined and diluted further with 1712 gof cresol-phenol solvent. The solids content was determined to be 34percent.

A 50 g sample of the 34 percent solution (containing 5 m moles ofdiamine) was diluted with 32 g of cresol-phenol solvent in a smallWaring Blender and stirred for 4 minutes.4,4'-Bismaleimidodiphenylmethane (2.2 g, 6.1 m moles) was added at 55°C. with stirring. Stirring was continued 2 minutes further with thetemperature at 60° C. The solution was drained into a jar. A sample wasbaked for 15 minutes at 200° C. in an aluminum cup. The film wasflexible to a 180° C. bend and strongly adhered to the cup.

The solution was heated for 2 1/4 hours in a 120° C. oven. It was thencoated on copper wire and cured on a wire tower to give a film of 1.8mil build which had cut-through of 300° C.

The present materials are useful as electrical insulating films, wireenamels, molding powders and adhesives. They are also useful in thepreparation of laminates and composite materials.

What we claim as new and desire to secure by Letters Patent of the United States is:
 1. A polymer selected from (a) the reaction product of (1) olefin terminated prepolymer prepared by reacting maleic anhydride and amine terminated prepolymer, said amine terminated prepolymer being prepared by reacting a material selected from dicarboxylic acid, dicarboxylic acid anhydride, tricarboxylic acid and tricarboxylic acid anhydride with simple polyamine having the formula

    X--R"--(NH.sub.2).sub.n

where R" is an organic radical, n is at least 2 and X is selected from hydrogen, amino group, substituted organic groups and unsubstituted organic groups and (2) simple polyamine as in (1) above and (b) the reaction product of (1) olefin terminated prepolymer as in (a) above and (2) amine terminated prepolymer as in (a) above, about equivalent proportions of the polymer forming ingredients being used.
 2. The polymeric reaction product of olefin terminated prepolymer and simple polyamine as in claim
 1. 3. The polymeric reaction product of amine terminated prepolymer and olefin terminated prepolymer as in claim
 1. 4. A polymer as in claim 1 wherein said simple polyamine is metaphenylene diamine.
 5. A polymer as in claim 1 wherein said simple polyamine is methylene dianiline.
 6. A polymer as in claim 1 wherein said simple polyamine is diaminodiphenyl sulfone. 